Air compressor assembly having enclosed unpainted air tank

ABSTRACT

An air compressor assembly having an unpainted air tank that is enclosed in a shroud. The air tank may be made of metal, plastic, or the like. In a preferred embodiment, the shroud is made of plastic. The shroud may also be made of metal or the like. The air compressor assembly according to the present invention may be formed in various styles, including a portable type air compressor assembly, a “pancake” type air compressor assembly, a “hot-dog” type air compressor assembly, a vertical “hot-dog” type air compressor assembly, a vertical stationary type air compressor assembly, a “double hot-dog” type air compressor assembly, and the like.

CROSS-REFERENCE TO RELATED DOCUMENTS

[0001] The present application claims the benefit under 35 U.S.C.§119(e) of U.S. Provisional Application Serial No. 60/408,860, filedSep. 6, 2002. Said U.S. Provisional Application Serial No. 60/408,860 isherein incorporated by reference in its entirety.

[0002] The present application herein incorporates the following UnitedStates Patent Applications by reference in their entirety: AttorneyDocket Number “Express Mail” Mailing Label No. Filing Date PTG 02-96-2EV 338 284 628 US Jun. 20, 2003 PTG 02-96-4 EV 338 284 605 US Jun. 20,2003

FIELD OF THE INVENTION

[0003] The present invention relates generally to the field of aircompressors, and particularly to an air compressor assembly having anunpainted air tank which is enclosed in a shroud.

BACKGROUND OF THE INVENTION

[0004] The supply of compressed air is an important consideration inhuman life. From residential use to industrial application, compressedair is utilized to perform many operations such as powering air toolsand sprayers. Since the air tank of a conventional air compressorassembly is generally visible to a user, manufacturers typically have topaint the outside surface of the air tank in color that satisfies theaesthetic requirement of their customers. Different customers may likedifferent color, and painting the air tank is an expensive andtime-consuming process. Thus the process of painting the air tank maygreatly decrease the manufacturing efficiency and increase themanufacturing cost. Moreover, because a conventional air tank isgenerally exposed to the outside air, it is easy for the air tank todissipate heat and thus for the moisture within the compressed airinside the tank to condense, which may cause tank corrosion.Furthermore, during air usage because an operator may be in directcontact with potentially hot tubing surfaces of the air compressorassembly, operator bum injuries may result.

[0005] Thus, it would be desirable to provide an air compressor assemblythat reduces the risk of operator bum injuries and has less tankcorrosion, and whose manufacturing process does not require the air tankbe painted.

SUMMARY OF THE INVENTION

[0006] Accordingly, the present invention is directed to an aircompressor assembly having an unpainted air tank that is enclosed in ashroud. The air tank may be made of steel, plastic, or the like. In apreferable embodiment, the shroud is made of plastic. The shroud mayalso be made of metal or the like.

[0007] According to the present invention, the air tank need not bepainted during the manufacturing process, because the air tank isenclosed in the shroud and is thus normally hidden from an outsideviewer. An unpainted hidden tank may increase the manufacturingefficiency and lower the cost. In the meantime, an unpainted hidden tankdoes not adversely affect customers' aesthetic requirement since thetank is typically hidden from the customers.

[0008] Moreover, the air compressor assembly enclosed in a shroud mayreduce the risk of operator burn injuries from potentially hot tubingsurfaces of the air compressor assembly during air usage, because theoperator is not in direct contact with the surfaces.

[0009] Furthermore, the air tank enclosed in a shroud may warm up morequickly than an exposed tank by absorbing heat from the air compressorassembly. The air tank also retains heat longer because of reducedconvection and radiation cooling to the outside air. By keeping the airtank warmer, the moisture within the compressed air in the air tank isless likely to condense, resulting in reduced tank corrosion.

[0010] The air compressor assembly according to the present inventionmay be formed in various styles, including a “pancake” type aircompressor assembly, a “hot-dog” type air compressor assembly, avertical “hot-dog” type air compressor assembly, a vertical stationarytype air compressor assembly, a “double hot-dog” type air compressorassembly, and the like.

[0011] It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and are not restrictive of the invention as claimed.The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate an embodiment of the invention andtogether with the general description, serve to explain the principlesof the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The numerous advantages of the present invention may be betterunderstood by those skilled in the art by reference to the accompanyingfigures in which:

[0013]FIG. 1 is an isometric view illustrating a portable air compressorassembly in accordance with an exemplary embodiment of the presentinvention;

[0014]FIG. 2 is a front elevation view of the portable air compressorassembly shown in FIG. 1;

[0015]FIG. 3 is a side elevation view of the portable air compressorassembly shown in FIG. 1;

[0016]FIG. 4 is an isometric view of an exemplary embodiment of theportable air compressor assembly shown in FIGS. 1 through 3, wherein afront shell of a shroud is removed for illustration of an air tank, anair compressor and a manifold assembly;

[0017]FIG. 4A is an isometric view of a further exemplary embodiment ofthe portable air compressor assembly shown in FIGS. 1 through 3, whereina front shell of a shroud is removed for illustration of an air tank, anair compressor and a manifold assembly;

[0018]FIG. 5A shows an exemplary conventional “pancake” type aircompressor assembly;

[0019]FIG. 5B shows an exemplary “pancake” type air compressor assemblyin accordance with the present invention, wherein the air compressorassembly shown in FIG. 5A is enclosed in a shroud;

[0020]FIG. 6A shows an exemplary conventional “hot-dog” type aircompressor assembly;

[0021]FIG. 6B shows an exemplary “hot-dog” type air compressor assemblyin accordance with the present invention, wherein the air compressorassembly shown in FIG. 6A is enclosed in a shroud;

[0022]FIG. 7A shows an exemplary conventional vertical “hot-dog” typeair compressor assembly;

[0023]FIG. 7B shows an exemplary vertical “hot-dog” type air compressorassembly in accordance with the present invention, wherein the aircompressor assembly shown in FIG. 7A is enclosed in a shroud;

[0024]FIG. 8A shows an exemplary conventional vertical stationary typeair compressor assembly; and

[0025]FIG. 8B shows an exemplary vertical stationary type air compressorassembly in accordance with the present invention, wherein the aircompressor assembly shown in FIG. 8A is enclosed in a shroud.

DETAILED DESCRIPTION OF THE INVENTION

[0026] Reference will now be made in detail to the presently preferredembodiments of the invention, examples of which are illustrated in theaccompanying drawings.

[0027] Referring generally to FIGS. 1 through 4, exemplary embodimentsof a portable air compressor assembly 100 in accordance with the presentinvention are shown. The portable air compressor assembly 100 mayinclude an air tank 102, an air compressor 104, and a manifold assembly106 assembled within a shroud or housing 108. The shroud 108 may be madeof plastic, metal, or the like. The shroud 108, which is preferably madeof plastic, includes a handle 118 allowing an operator to lift andtransport the portable air compressor assembly 100 from place to place,and a control panel 120 providing controls for the portable aircompressor assembly 100. In the exemplary embodiments illustrated, thecontrol panel 120 may include an on/off switch 122, a pressure regulator124, a pressure gauge 126, a pressure relief safety valve 128, and thespeed control switch 116. However, it will be appreciated that thecontrol panel 120 may provide other controls depending on designpreferences.

[0028] As shown in FIGS. 4 and 4A, the air compressor 104 may include acompressor 110 having one or more pistons 112 driven by a motor orengine 114. For example, in the exemplary embodiment illustrated, theair compressor 104 may include a single piston compressor 110 having asingle piston driven by a universal electric motor 114. By employing auniversal electric motor 114, the speed at which the motor 114 operates,and thus the speed at which the piston 112 is reciprocated, may bevaried by controlling the voltage supplied to the motor 114. In thismanner, the air flow rate supplied by the air compressor 104 to the airtank 102 may be varied. For example, in the embodiments illustrated inFIGS. 1 through 4, a speed control switch 116 is provided, which allowsan operator to select between a high speed operation mode whereinmaximum air flow is supplied to the air tank 102 and a low speedoperating mode wherein the compressor 110 runs more slowly reducing thenoise generated by the air compressor 104.

[0029]FIG. 4 shows an exemplary embodiment of the portable aircompressor assembly 100 shown in FIGS. 1 through 3, wherein a frontshell of the shroud 108 is removed for illustration of the air tank 102,the air compressor 104 and the manifold assembly 106. The tank 102 maybe made of metal, plastic, and the like and its outer surface was notpainted during the manufacturing process. The air tank 102 has an airinlet port 130 and an air outlet port 132, both positioned at the wallof the air tank 102. In the exemplary embodiment shown in FIG. 4, theair inlet port 130 is located at an upper wall of the air tank 102, andthe air outlet port 132 is located at a lower wall of the air tank 102.It is understood that the locations of the air inlet port 130 and theair outlet port 132 at the wall of the air tank 102 may change withoutdeparting from the scope and spirit of the present invention. The airinlet port 130 and the air outlet port 132 are openings extendingthrough the wall of the air tank 102.

[0030] As shown in FIG. 4, the air compressor 104 may provide air to theair tank 102 through the tubing 136 and the air inlet port 130. Theremay exist a check valve (not shown) inside the air inlet port 130, whichallows air to flow from the air compressor 104 to the air tank 102 butprevents air from flowing from the air tank 102 to the air compressor104. The air tank 102 may be connected to the manifold assembly 106through tubing 134. During air usage, compressed air being released fromthe air tank 102, because of its high pressure, may drive condensateaccumulated in the tank 102 out through the air outlet port 132. Thecompressed air being released may mix with the discharged condensate andbe used in air powered tools. Preferably, the discharged condensate isrouted through the tubing 134, the manifold assembly 106 and anyattached air hose to the air powered tools.

[0031]FIG. 4A shows a further exemplary embodiment of the portable aircompressor assembly 100 shown in FIGS. 1 through 3, wherein a frontshell of the shroud 108 is removed for illustration of the air tank 102,the air compressor 104 and the manifold assembly 106. The tank 102 maybe made of metal, plastic, and the like and its outer surface was notpainted during the manufacturing process. The air tank 102 has an airaccess port 132 positioned at the wall of the air tank 102. In theexemplary embodiment shown in FIG. 4A, the air access port 132 islocated at a lower wall of the air tank 102. It is understood that thelocation of the air access port 132 at the wall of the air tank 102 maychange without departing from the scope and spirit of the presentinvention. The air access port 132 is an opening extending through thewall of the air tank 102.

[0032] As shown in FIG. 4A, the air compressor 104 is connected to themanifold assembly 106 through the tubing 136, and the air tank 102 isconnected to the manifold assembly 106 through the air access port 132and tubing 134. There may exist a check valve (not shown) inside themanifold assembly 106, which allows air to flow from the air compressor104 to the manifold assembly 106 but prevents air from flowing from themanifold assembly 106 to the air compressor 104. Thus, the aircompressor 104 may supply air to the air tank 102 through the tubing136, the manifold assembly 106, the tubing 134 and the air access port132. Compressed air may be released from the air tank 102 through theair access port 132, the tubing 134, the manifold assembly 106, and anyattached air hose to the air powered tools. During air usage, compressedair being released from the air tank 102, because of its high pressure,may drive condensate accumulated in the tank 102 out through the airaccess port 132. The compressed air being released may mix with thedischarged condensate and be used in air powered tools.

[0033] In the exemplary embodiments illustrated in FIGS. 4 and 4A, theair tank 102 is enclosed within and supported by the shroud 108. Theshroud 108 also encloses the air compressor 104, the manifold assembly106, the tubing 134, the tubing 136, and electrical wiring. Because theair tank 102 is normally invisible to viewers of the shroud 108 fromoutside of the assembled shroud, the air tank 102 may be fabricated andassembled into the unit without first being painted. In this manner,processing through an expensive and time consuming painting process iseliminated, improving manufacturing efficiencies to lower cost.Moreover, all potentially hot tubing 136 between the air compressor 104and the air tank 102 is enclosed, thereby reducing the risk of operatorburn injuries from hot surfaces. An additional advantage of the enclosedair tank 102 is that the air tank 102 may warm up more quickly than anexposed tank by absorbing heat from the air compressor 104. The air tank102 also retains heat longer because of reduced convection and radiationcooling to the outside air. By keeping the air tank 102 warmer, the tank102 is less likely to condense moisture, resulting in reduced tankcorrosion.

[0034] It is understood that the portable air compressor assembly 100 inaccordance with the present invention may have other configurationswithout departing from the scope and spirit of the present invention.For example, the unpainted enclosed air tank 102 may have at the tankbottom a conventional drain valve instead of the automatic drain device(e.g., the air outlet port 132 and the tubing 134) to drain thecondensate in the tank 102. Moreover, the portable air compressorassembly 100 may have the configuration shown in FIGS. 8 and 9 ofco-pending U.S. Patent Application (“Express Mail” Mailing Label No. EV338 284 628 US, filed Jun. 20, 2003), wherein the air tank was notpainted during the manufacturing process. The portable air compressorassembly 100 may also be partially enclosed. For example, a shroud mayenclose the unpainted air tank 102 only and thus hide the air tank 102from an outside viewer, while the air compressor 104 and the manifoldassembly 106 may be exposed to the air. It is understood that a portableair compressor assembly means an air compressor assembly that can becarried and/or moved with ease, and not as a structural limitation.

[0035] Referring generally now to FIGS. 5 through 8, exemplary aircompressor assemblies in various styles in accordance with the presentinvention are shown. Referring to FIG. 5A, an exemplary conventional“pancake” type air compressor assembly 500 is shown. The air compressorassembly 500 may include an air tank 502 for storing compressed air, anair compressor 512 for supplying compressed air to the air tank 502, andpiping or tubing 514. The air tank 502 is a flattened oval tank, oftenreferred to informally in the art as a “pancake” style tank. The airtank 502 may be made of plastic, metal such as steel, or the like andwas painted to satisfy customers' aesthetic requirements during themanufacturing process. The air tank 502 is directly exposed to theoutside air. The air compressor assembly 500 may also include a wheelassembly 504 for transporting the air compressor assembly 500, and acontrol panel 510 allowing an operator to control the air compressorassembly 500.

[0036]FIG. 5B shows an exemplary “pancake” type air compressor assembly550 in accordance with the present invention. Here, the air compressorassembly 500 shown in FIG. 5A, including the air tank 502, the aircompressor 512 and the connecting piping or tubing 514, is enclosed in ashroud 508. However, the outer surface of the air tank 502 was notpainted during the manufacturing process. The shroud 508 may be made ofmetal such as steel, plastic, or the like. The wheel assembly 504 of theair compressor assembly 500 is not enclosed so that the air compressorassembly 550 may be easily transported. And the control panel 510 isalso not enclosed so that the air compressor assembly 550 may becontrolled from outside by an operator.

[0037] Referring to FIG. 6A, an exemplary conventional “hot-dog” typeair compressor assembly 600 is shown. The air compressor assembly 600may include an air tank 602 for storing compressed air, an aircompressor 612 for supplying compressed air to the air tank 602, andpiping or tubing 614. The air tank 602 is a horizontally disposed,cylindrical compressed air tank, typically referred to informally in theart as a “hot-dog” style tank. The -air tank 602 may be made of plastic,metal such as steel or the like and was painted to satisfy customers'aesthetic requirement during the manufacturing process. The air tank 602is directly exposed to the outside air. The air compressor assembly 600may also include a wheel assembly 604 and a handle assembly 606 fortransporting the air compressor assembly 600, and a control panel 610allowing an operator to control the air compressor assembly 600.

[0038]FIG. 6B shows an exemplary “hot-dog” type air compressor assembly650 in accordance with the present invention. Here, the air compressorassembly 600 shown in FIG. 6A, including the air tank 602, the aircompressor 612 and the connecting piping or tubing 614, is enclosed in ashroud 608. However, the outer surface of the air tank 602 was notpainted during the manufacturing process. The shroud 608 may be made ofmetal such as steel, plastic, or the like. The wheel assembly 604 andthe handle assembly 606 of the air compressor assembly 600 are notenclosed so that the air compressor assembly 650 may be easilytransported. And the control panel 610 is also not enclosed so that theair compressor assembly 650 may be controlled from outside by anoperator.

[0039] Referring to FIG. 7A, an exemplary conventional vertical“hot-dog” type air compressor assembly 700 is shown. The air compressorassembly 700 may include an air tank 702 for storing compressed air, anair compressor 712 for supplying compressed air to the air tank 702, andpiping or tubing 714. The air tank 702 is a vertically disposed,cylindrical compressed air tank, typically referred to informally in theart as a vertical “hot-dog” style tank. The air tank 702 may be made ofplastic, metal such as steel, or the like and was painted according tocustomers' aesthetic requirement during the manufacturing process. Theair tank 702 is directly exposed to the outside air. The air compressorassembly 700 may also include a wheel assembly 704 and a handle assembly706 for transporting the air compressor assembly 700, and a controlpanel 710 allowing an operator to control the air compressor assembly700.

[0040]FIG. 7B shows an exemplary vertical “hot-dog” type air compressorassembly 750 in accordance with the present invention. Here, the aircompressor assembly 700 shown in FIG. 7A, including the air tank 702,the air compressor 712 and the connecting piping or tubing 714, isenclosed in a shroud 708. However, the outer surface of the air tank 702was not painted during the manufacturing process. The shroud 708 may bemade of metal such as steel, plastic, or the like. The wheel assembly704 and the handle assembly 706 of the air compressor assembly 700 arenot enclosed so that the air compressor assembly 750 may be easilytransported. And the control panel 710 is also not enclosed so that theair compressor assembly 750 may be controlled from outside by a user.

[0041] Referring to FIG. 8A, an exemplary conventional verticalstationary type air compressor assembly 800 is shown. The air compressorassembly 800 may include an air tank 802 for storing compressed air, anair compressor 812 for supplying compressed air to the air tank 802, andpiping or tubing 814. The vertically disposed air tank 802 may be madeof plastic, metal such as steel, or the like and was painted to satisfycustomers' aesthetic requirement during the manufacturing process. Theair tank 802 is directly exposed to the outside air. The air compressorassembly 800 is stationary, that is, it may not be easily transported.The air compressor assembly 800 may include a control panel 810,allowing an operator to control the air compressor assembly 800.

[0042]FIG. 8B shows an exemplary vertical stationary type air compressorassembly 850 in accordance with the present invention. Here, the aircompressor assembly 800 shown in FIG. 8A, including the air tank 802,the air compressor 812 and the connecting piping or tubing 814, isenclosed in a shroud 808. However, the outer surface of the air tank 802was not painted during the manufacturing process. The shroud 808 may bemade of metal such as steel, plastic, or the like. The control panel 810is not enclosed so that the air compressor assembly 850 may becontrolled from outside by an operator.

[0043] As shown in FIGS. 5 through 8, exemplary air compressorassemblies according to the present invention have a shroud thatencloses the unpainted air tank, the air compressor, and the tubing andpiping. In these embodiments, since the air tank is enclosed in theshroud and thus hidden from an outside viewer, the air tank need not bepainted during the manufacturing process. Moreover, since the aircompressor and the tubing or piping are also enclosed in the shroud, theoperator is thus not in direct contact with the potentially hot tubingor piping surfaces. Therefore, the risk of operator burn injuries duringair usage from the potentially hot tubing or piping surfaces may bereduced. Furthermore, the air tank may warm up more quickly than anexposed tank by absorbing heat from the air compressor and the tubing orpiping. The air tank also retains heat longer because of reducedconvection and radiation cooling to the outside air. By keeping the airtank warmer, the moisture within the compressed air in the air tank isless likely to condense, resulting in reduced tank corrosion.

[0044] It is understood that the shroud of the air compressor assemblyin accordance with the present invention may also enclose the unpaintedair tank only (e.g., neither the air compressor nor the piping or tubingis enclosed) without departing from the scope and spirit of the presentinvention. It is also understood that the air compressor assemblyaccording to the present invention may also have air tanks of otherconfigurations. For example, it may have two horizontally disposedcylindrical compressed air tanks, positioned side by side in avertically oriented “double hot-dog” configuration.

[0045] It is also understood that the specific order or hierarchy ofsteps in the methods disclosed are examples of exemplary approaches.Based upon design preferences, it is understood that the specific orderor hierarchy of steps in the method can be rearranged while remainingwithin the scope of the present invention. The accompanying methodclaims present elements of the various steps in a sample order, and arenot meant to be limited to the specific order or hierarchy presented.

[0046] It is believed that the present invention and many of itsattendant advantages will be understood by the foregoing description. Itis also believed that it will be apparent that various changes may bemade in the form, construction and arrangement of the components thereofwithout departing from the scope and spirit of the invention or withoutsacrificing all of its material advantages. The form herein beforedescribed being merely an explanatory embodiment thereof, it is theintention of the following claims to encompass and include such changes.

What is claimed is:
 1. An air compressor assembly, comprising: an air tank for containing air at an elevated pressure, the air tank having an unpainted outer surface during a manufacturing process; a shroud enclosing the air tank; and an air compressor for supplying air for storage in the air tank.
 2. The air compressor assembly of claim 1, wherein the shroud encloses the air compressor.
 3. The air compressor assembly of claim 1, wherein the air compressor assembly is of a “pancake” type.
 4. The air compressor assembly of claim 1, wherein the air compressor assembly is of a “hot-dog” type.
 5. The air compressor assembly of claim 1, wherein, the air compressor assembly is of a vertical “hot-dog” type.
 6. The air compressor assembly of in claim 1, wherein the air compressor assembly is of a “double hot-dog” type.
 7. The air compressor assembly of claim 1, wherein the air compressor assembly is of a vertical stationary type.
 8. The air compressor assembly of claim 1, wherein the air tank is made of metal.
 9. The air compressor assembly of claim 7, wherein the air tank is made of steel.
 10. The air compressor assembly of claim 1, wherein the air tank is made of plastic.
 11. The air compressor assembly of claim 1, wherein the shroud is made of plastic.
 12. The air compressor assembly of claim 1, wherein the shroud is made of metal.
 13. A portable air compressor assembly, comprising: an air tank for containing air at an elevated pressure, the air tank having a first air access port thereof and having an unpainted outer surface during a manufacturing process; a shroud enclosing the air tank; and an air compressor for supplying air for storage in the air tank.
 14. The portable air compressor assembly of claim 13, wherein through the first air access port air is supplied to and released from the air tank.
 15. The portable air compressor assembly of claim 14, wherein the first air access port is located at a bottom wall of the air tank.
 16. The portable air compressor assembly of claim 14, wherein the first access port is located at a top wall of the air tank and is an upper open end of a centrally hollow conduit positioned inside the air tank.
 17. The portable air compressor assembly of claim 13, wherein the air tank has a second air access port.
 18. The portable air compressor assembly of claim 17, wherein through the first air access port air is supplied to the air tank by the air compressor and through the second air access port air is released from the air tank.
 19. The portable air compressor assembly of claim 18, wherein the first air access port is located at a top wall of the air tank and the second air access port is located at a bottom wall of the air tank.
 20. The portable air compressor assembly of claim 13, wherein the shroud encloses the air compressor.
 21. The portable air compressor assembly of claim 13, wherein the shroud is made of plastic.
 22. The portable air compressor assembly of claim 13, wherein the shroud is made of metal.
 23. The portable air compressor assembly of claim 13, wherein the air tank is made of metal.
 24. The portable air compressor assembly of claim 13, wherein the air tank is made of plastic.
 25. The portable air compressor assembly of claim 13, wherein the shroud includes a handle for allowing the portable air compressor assembly to be lifted and transported from place to place.
 26. The portable air compressor assembly of claim 13, further comprises a control panel to allow operation of the portable air compressor assembly to be controlled.
 27. A method for manufacturing an air compressor assembly, comprising: providing an air tank for containing air at an elevated pressure, the air tank having an unpainted outer surface; providing an air compressor for supplying air for storage in the air tank; and enclosing the air tank with a shroud.
 28. The method of claim 27, further comprising enclosing the air compressor assembly in the shroud.
 29. The method of claim 27, wherein the air compressor assembly is of a portable type.
 30. The method of claim 29, wherein the shroud is made of plastic.
 31. The method of claim 27, wherein the air compressor assembly is of a “pancake” type.
 32. The method of claim 27, wherein the air compressor assembly is of a “hot-dog” type.
 33. The method of claim 27, wherein the air compressor assembly is of a vertical “hot-dog” type.
 34. The method of claim 27, wherein the air compressor assembly is of a “double hot-dog” type.
 35. The method of claim 27, wherein the air compressor assembly is of a vertical stationary type. 